Separation of co2 from gas mixtures

ABSTRACT

Processes for separating carbon dioxide from a gas mixture that comprises CO 2  and N 2  that are based upon formation of gas hydrates, and systems useful for implementing such processes, are disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/437,723, filed on Dec. 22, 2016, the entire contents of which areincorporated herein by reference.

FIELD

This disclosure relates to separation of CO₂ from gas mixturescomprising N₂, such as combustion gases, which can be power plant fluegases.

BACKGROUND

Separation of CO₂ from power plant flue gas and other gas mixtures thatresult from industrial processes and other fixed point sources iscritical for reducing greenhouse gas emissions, and especially suchemissions due to electricity generation. Technologies exist today toremove CO₂ from flue gas, such as absorptive technologies based onamines, but these technologies are costly and significantly reduceoverall power plant efficiency. An additional challenge of today's CO₂separation processes is that subsurface geologic structures must bepresent and able to receive CO₂. Locations which do not have suitablegeologic formations will not be able to sequester the CO₂, even if itcan be separated from the flue gas mixture. Thus, there exists a need todevelop an improved technology capable of not only removing CO₂ fromflue gas or other industrially produced waste gas mixtures, but alsoproviding the captured CO₂ in a form, such as a solid hydrate, that isamenable to sequestration by methods other than injection intosubsurface geologic formations.

U.S. Pat. No. 5,434,330 describes a process for separating clathrateforming gases by first contacting a gaseous stream with an aqueoussolvent to form a hydrate suspension. The clathrate forming gases arethen selectively recovered by exposing the hydrate suspension (or theseparated hydrate) to increased temperature and/or reduced pressure.

US20130012751 describes a process by which the corrosive elements of agas stream (e.g. CO₂, H₂S) can be separated from hydrocarbon gases in ahydrate-based separator using a similar approach as outlined in the U.S.Pat. No. 5,434,330. The process yields a gas product, e.g. a purifiednatural gas product, that is less corrosive due to removal of H₂S andCO₂ from the natural gas.

SUMMARY

Disclosed is a technology based on hydrate-based gas separation in whichCO₂ is preferentially captured into a hydrate structure to selectivelyremove CO₂ from a gas stream also including N₂ and/or O₂. The disclosedprocess and apparatus for implementing it provide improved separation ofCO₂ from N₂ and O₂ from mixed gases, such as power plant flue gas, andimproved energy and input material utilization. The CO₂ hydrate productof the process can be transported to suitable long term storagelocations such as geologic formations or marine hydrate reservoirs.Alternatively, the CO₂ hydrate product can be decomposed (before orafter transport to another site) and the resulting CO₂ gas can be usedin subsequent industrial processes or the CO₂ hydrate can besequestered. The N₂-rich product gas is sufficiently pure to be releasedto the atmosphere directly, or can be transported for use as anindustrial gas or to drive a turbine, providing further energy recoveryfrom the process.

Thus, in one aspect, a system for separating CO₂ from a gas mixturecomprising CO₂ and N₂, such as combustion product or other gas, caninclude a hydrate formation reactor (HFR) that comprises an outer vesselconfigured:

with a plurality of stages arranged with a first stage proximal a firstend of the vessel and second and any subsequent stages successively moreproximal a second end of the vessel;

one or more gas feed inlets placed at a distance from the first end ofthe vessel the same as said distance of a stage that is a second orsubsequent stage and configured to feed a gas stream into the vessel;

one or more aqueous phase inlets configured to feed an aqueous phaseinto the second end of the vessel or proximate thereto;

one or more hydrate slurry outlets configured to permit a draw off anaqueous phase hydrate slurry stream from the first end of the vessel orproximate thereto;

one or more gas product outlets configured to draw off a gas productstream from the second end of the vessel or proximate thereto; and

a temperature control system effective to establish a temperaturegradient or a series of temperature steps from a first temperature T₁ ina region proximate to the first end of the vessel to a secondtemperature T₂ in a region proximate to the second end of the vessel andcontrolling the temperature at each of the stages, wherein T₁>T₂;

wherein the gas stream and the aqueous phase flow in a countercurrentmanner through the vessel.

A gas feed to the hydrate formation reactor can include an inlet foradding a hydrate promoter to the gas feed. Such inlet for adding ahydrate promoter can include a mixer.

An aqueous phase inlet can be configured to input fresh aqueous phaseinto the HFR or to input recycled aqueous phase into the HFR. An aqueousphase inlet can be configured to include an inlet for adding a hydratepromoter to the aqueous phase. Such inlet for adding a hydrate promotercan include a mixer.

The CO₂ separation system can further include a solid-liquid separatorfor separating an aqueous hydrate slurry drawn from the hydrateformation reactor into an aqueous phase product and a solid hydrate, andthen can also include an aqueous phase recirculating line that feeds theaqueous phase product of the solid-liquid separator fully or partiallyinto the second end of the vessel or proximate thereto. The aqueousphase recirculating line can include a cooling plant for cooling theaqueous phase liquid product prior to introducing the recirculatedaqueous phase back into the hydrate formation reactor. The aqueous phaserecirculating line can alternatively or additionally include an inletfor adding a hydrate promoter to the recirculating aqueous phase.

In a further aspect, the present disclosure provides a hydrateformation-based process for purifying CO₂ from a gas comprising N₂wherein the process comprises intimately contacting a feed gas streamcomprising CO₂ and N₂ gases and a aqueous phase stream in acountercurrent flow to form a CO₂-rich hydrate in the aqueous phase, atemperature T_(f) being maintained at a gas feed stage f in thecountercurrent flow, a temperature T₂ such that T₂<T_(f) beingmaintained at a stage n>f, and a temperature T₁ being maintained at astage m≤f such that T₁≥T_(f); wherein: T₂ is in the range from theincipient vapor formation temperature for CO₂ to the incipient hydrateformation temperature for CO₂ at the operating pressure of the process,and T₁ is a temperature at or below a temperature of convergence of theincipient CO₂ hydrate formation and incipient CO₂ vapor formation curvesat the operating pressure of the process. Typically, high pressureoperation, e.g. 2200 psia or above (depending on the composition of theinput gas—for example for separating flue gas from a natural gascombined cycle (NGCC) power plant), is required for effective separationof CO₂ from N₂ in a hydrate formation-based process. Thus, one or morehydrate promoters can optionally be added to the gas feed stream of theprocess. Additionally or alternatively, one or more hydrate promoterscan be added to the aqueous phase used in the process. These additiveshave the effect of lowering the pressure, or raising the temperature, atwhich the process can operate (thermodynamic hydrate promoters) orimproving the kinetics of hydrate formation (kinetic hydrate promoters).

The CO₂-rich hydrate product of the hydrate formation reactor can betransported as a source of CO₂ or sequestered to store the CO₂ trappedin the hydrate, or can be decomposed into a CO₂-rich gas for use inother industrial processes.

The N₂-rich gas product of the process obtained after separation of thegas stream from the aqueous phase can be used in other industrialprocesses, or can be stored at a pressure above atmospheric pressure ortransported directly from the hydrate formation reactor to be used todrive a turbine or other pressure-differential engine to generateelectricity or perform other useful work.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph of a N₂—CO₂ hydrate formation phase diagram at 33° F.

FIG. 2 is a graph of a hydrate formation phase diagram at 2200 psia.

FIG. 3 illustrates various hydrate forms. (E. Dendy Sloan Jr.,“Fundamental principles and applications of natural gas hydrates”,Nature, vol. 426, p. 353 (2003).)

FIG. 4 is an illustration of a system for separating CO₂ from a mixtureof gases.

FIG. 5 is an illustration of another system for separating CO₂ from amixture of gases.

FIG. 6 illustrates a determination of staging in a CO₂ separatingprocess.

FIG. 7 is a flow chart of a CO₂ separating process.

FIG. 8 is an illustration of an amine-based system for capturing CO₂that can be used to concentrate CO₂ in a feed gas to a hydrate-based CO₂separation process.

FIG. 9 is a plot of incipient hydrate formation pressure vs. temperaturefor a gas feed having component ratios of 9.5 moles N₂:0.5 moles CO₂:100moles water.

FIG. 10 shows hydrate formation phase diagrams for a 17:83 mol % CO₂—N₂mixture and for such mixtures to which varying amounts of THF are added.S. Kang, H. Lee, C. Lee, and W. Sung, “Hydrate phase equilibria of theguest mixture containing CO₂, N₂, and Tetrahydrofuran”, Fluid PhaseEquilibria, vol. 185, p. 101 (2001).

FIG. 11 shows the effect of lowering the operating pressure on theoperating window for a hydrate-based gas separation.

FIG. 12 shows the effect of addition of H₂S to the feed gas on theoperating window for a hydrate-based gas separation.

FIG. 13 shows the effect of lowering the operating pressure and H₂Saddition to the feed gas on the operating window for a hydrate-based gasseparation.

FIG. 14 shows the effect of addition of isobutane to the feed gas on theoperating pressure for a hydrate-based gas separation.

DETAILED DESCRIPTION Definitions

In the following detailed description section, specific embodiments ofthe present techniques are described. However, to the extent that thefollowing description is specific to a particular embodiment or aparticular use of the present techniques, this is intended to be forexemplary purposes only and simply provides a description of theexemplary embodiments. Accordingly, the apparatuses and processesencompassed are not limited to the specific embodiments described below,but rather, include all alternatives, modifications, and equivalentsfalling within the true spirit and scope of the appended claims.

At the outset, for ease of reference, certain terms used in thisapplication and their meanings as used in this context are set forth. Tothe extent a term used herein is not defined below, it should be giventhe broadest definition persons in the pertinent art have given thatterm as reflected in at least one printed publication or issued patent.Further, the present techniques are not limited by the usage of theterms shown below, as all equivalents, synonyms, new developments, andterms or techniques that serve the same or a similar purpose areconsidered to be within the scope of the present claims.

As used herein, “about” is a preposition describing some quantity orparameter value, and indicates that some variation around the statedamount or value is included. Generally, the degree of variation intendedto be encompassed is that which would be understood by one of ordinaryskill in the art not to materially affect the performance of anapparatus or device or a characteristic of a material or compositiondescribed by the amount or parameter. The degree of variationencompassed can be influenced by the ability of an artisan or ordinaryskill to measure or control the amount or value in operation of aprocess or production of a substance or composition. In some instances,variation of up to 10% is envisioned. In some instances variation of upto 5% is envisioned. In some instances variation of up to 1% isenvisioned. In some instances, variation of up to 0.5% is envisioned. Insome instances, variation of up to 0.1% is envisioned. In the specificinstance of the temperature of each stage of a HFR, “about” is intendedto encompass 2-3% variation.

As used herein, an “aqueous phase” is water, a water solution of one ormore dissolved substances, or either of these that includes a suspensionof hydrate particles. The “dissolved substances” of a water solution caninclude molecules of gas partitioned into the aqueous phase from a gasbeing separated by the presently disclosed process. “Dissolvedsubstances” can also include salts and organic molecules, either addedto or originally present in the water forming the aqueous phase (forexample substances present in seawater that might be used as the aqueousphase in some embodiments). “Dissolved substances” can also includethermodynamic hydrate promoters and kinetic hydrate promoters added tothe aqueous phase. “Dissolved substances” can also include dissolvedclathrates that have not agglomerated into substantial particles.“Hydrate particles” can include particles of sufficiently small size toremain suspended by flow of a slurry of the particles in the aqueousphase, and can also include aggregates of clathrate particles that haveaccreted to a size visible to the naked eye or larger, e.g.

as to settle from a standing aqueous phase under the influence ofgravity. Hydrate collected from disclosed processes and apparatus can bein solid form of substantial mass.

As used herein, a “clathrate” is a weak composite made of a hostcompound that forms a basic framework and a guest compound that is heldin the host framework by intermolecular interaction, such as hydrogenbonding, Van der Waals forces, and the like. Clathrates may also becalled “host-guest complexes”, “inclusion compounds”, and “adducts”. Asused herein, “clathrate” and “hydrate” are interchangeable terms used toindicate a clathrate having a basic framework made from water as thehost compound. A hydrate is a crystalline solid which looks like ice,and forms when water molecules form a cage-like structure around a“hydrate-forming constituent.”

Formation of a hydrate or clathrate is described herein as a “reaction”,since a stable structure is formed (under appropriate conditions) fromtwo previously separated compounds, although no chemical bonds arechanged.

FIG. 3 shows some various framework structures of water-moleculeclathrates and examples of molecular guests that can be found withinthem.

As used herein, a “hydrate-forming constituent” refers to a compound ormolecule in a fluid, including natural gas, that forms hydrate atelevated pressures and/or reduced temperatures. Illustrativehydrate-forming constituents include hydrocarbons such as methane,ethane, propane, butane, neopentane, ethylene, propylene, isobutylene,cyclopropane, cyclobutane, cyclopentane, cyclohexane, and benzene.Hydrate-forming constituents can also include non-hydrocarbons, such asoxygen, nitrogen, hydrogen sulfide, carbon dioxide, sulfur dioxide, andchlorine.

As used herein, a “compressor” is a machine that increases the pressureof a gas by the application of work (compression). Accordingly, a lowpressure gas (for example, at 5 psig) may be compressed into ahigh-pressure gas (for example, at 1000 psig) for transmission through apipeline, injection into a well, or other processes.

As used herein, a “column”, “tower” or “reactor” means a fractionationcolumn or zone, i.e., a contacting column or zone, wherein liquid andvapor phases can be counter-currently contacted to effect separation ofcompounds in a mixture of phases. For example, a separation in avapor-liquid-hydrate system may be performed by contacting of the vaporand liquid phases (which can include hydrate under appropriateconditions) on a series of vertically spaced trays or plates mountedwithin a column and/or on packing elements such as structured or randompacking. Further, a separation of compounds in a mixture of solid,liquid, and vapor phases may be effected by a contacting countercurrentflow of the solid and/or liquid phases (which may contain hydrate) in anopposite direction to a vapor phase.

As used herein, a “geologic formation” is any finite subsurface region.A geologic formation may encompass a large open space, either naturallyor man-made, and/or may contain one or more hydrocarbon containinglayers, one or more non-hydrocarbon containing layers, an overburden,and/or an underburden of any subsurface geologic formation. An“overburden” and/or an “underburden” is geological material above orbelow the geologic formation of interest.

As used herein, the term “gas” is used interchangeably with “vapor,” andmeans a substance or mixture of substances in the gaseous state asdistinguished from the liquid or solid state. Likewise, the term“liquid” means a substance or mixture of substances in the liquid statas distinguished from the gas or solid state. As used herein, “fluid” isa generic term that may include either a gas or vapor.

As used herein, “kinetic hydrate promoter” (“KHP”) refers to a moleculeand/or compound or mixture of molecules and/or compounds capable ofincreasing the rate of hydrate formation in a fluid that is eitherliquid or gas phase. A kinetic hydrate promoter can be a solid or liquidat room temperature and/or operating conditions.

As used herein, the term “minimum effective operating pressure” refersto the pressure below which hydrates do not form in fluids containinghydrate forming constituents during the time the fluids are resident ina vessel or line.

As used herein, the term “maximum effective operating temperature”refers to the temperature above which hydrates do not form in fluidscontaining hydrate forming constituents during the time the fluids areresident in a vessel or line. For thermodynamic promotion of hydrateformation only, the maximum effective operating temperature is higherthan the maximum effective operating temperature in the absence of theaddition of a THP. When a kinetic hydrate promoter is added togetherwith a THP, the maximum effective operating temperature is typicallyhigher than the thermodynamically promoted hydrate formationtemperature.

As used herein, a “McCabe-Thiele plot” is a graph of an equilibriumconcentration between two chemical components showing the concentrationratio of the components in each of two phases. In the graph, operatinglines are used to define the mass balance relationships between thecomponents. A McCabe-Thiele plot can be used to design a separationsystem based on the different concentrations of each of the componentsin each of the different phases. While McCabe-Thiele plots are generallyused to design distillation columns based on vapor-liquid equilibriums,they can be applied to separations base on any phase equilibrium, suchas the clathrate-liquid equilibrium discussed herein.

Construction of a McCabe-Thiele plot from equilibrium calculations isconsidered to be within the skill of the ordinary artisan. Avapor-liquid equilibrium curve can be constructed to from a mixturephase diagram. (W. L. McCabe & E. W. Thiele, Industrial and EngineeringChemistry, vol., pp. 605-611 (1925).—see alsohttps://en.wikipedia.org/wiki/McCabe%E2%80%93Thiele_method.)

As used herein, a “plant” is a known apparatus or a collection of knownapparatuses operably connected to perform a stated function. Forexample, a “cooling plant” will include equipment for chilling of aliquid passing through the cooling plant. A “facility” is a collectionof plants that together accomplish one or more functions. In itsbroadest sense, the term plant I applied to any equipment that may bepresent along a flow path of a system as disclosed herein.

As used herein, “pressure” is the force exerted per unit area by the gason walls enclosing a volume. Pressure can be shown as pounds per squareinch (psi). “Atmospheric pressure” refers to the local pressure of theair. “Absolute pressure” (psia) refers to the sum of the atmosphericpressure (14.7 psia at standard conditions) plus the gage pressure(psig). “Gauge pressure” (psig) refers to the pressure measured by agauge, which indicates only the pressure exceeding the local atmosphericpressure (i.e., a gauge pressure of 0 psig corresponds to an absolutepressure of 14.7 psia). The term “vapor pressure” has the usualthermodynamic meaning. For a pure component in an enclosed system at agiven pressure, the component vapor pressure is essentially equal to thetotal pressure in the system.

As used herein, a “stage” in a column or reactor is a zone of controlledtemperature within the reactor. The temperature to be set at each stagein the reactor can be determined by calculating phase diagrams forvapor-liquid (v-l), vapor-liquid-hydrate (v-l-h) and liquid-hydrate(l-h) phase diagrams for a feed gas composition, of the two gases to beseparated (N₂ and CO₂, for example, as below) for mol % of one of thegases to be separated from the feed vs. temperature at a given pressure.A temperature for the first stage can be selected by picking atemperature between the equilibrium incipient hydrate curve andincipient vapor curve at the composition desired in the hydrate phase. Atemperature of the last stage is selected by picking the temperature onthe incipient vapor curve at the composition desired in the gas phase.Temperatures of intermediate phases, if any, are identified by notingthe composition of the incipient vapor at the temperature selected forthe first stage, then noting the temperature of the incipient hydratecurve at this composition as the temperature for the second stage. Thetemperature of the third stage is selected by noting the composition atthe incipient vapor curve at the temperature of the second stage, thennoting the temperature of the incipient hydrate curve at thiscomposition, etc.

Stages in a hydrate formation reactor are implemented by establishing azone of controlled temperature at a particular section of a hydrateforming reactor, as described further below.

As used herein, “substantial” when used in reference to a quantity oramount of a material, or a specific characteristic thereof, refers to anamount that is sufficient to provide an effect that the material orcharacteristic was intended to provide. The exact degree of deviationallowable may in some cases depend on the specific context.

As used herein, “thermodynamic hydrate promoter” (THP) refers to amolecule and/or compound, or mixture of molecules and/or compoundscapable of reducing the hydrate formation pressure (at a giventemperature) in a fluid that is either liquid or gas phase. The additionof a THP to the fluid also has the effect of raising the temperature atwhich hydrates form at a given pressure.

The effect of adding a hydrate promoter to the process is shown, forexample, in FIG. 10, showing the effect on a gas separation of addingvarying amounts of Tetrahydrofuran (THF) to a binary mixture of CO₂ andN₂.

A system for separation of CO₂ from combustion product or other gasesincludes a hydrate formation reactor in which CO₂ from the combustiongas is partitioned into a hydrate phase by a countercurrent flow againstan aqueous phase. The hydrate formation reactor comprises an outervessel configured:

with a plurality of stages arranged with a first stage proximal a firstend of the vessel and second and any subsequent stages successively moreproximal a second end of the vessel;

one or more gas feed inlets placed at a distance distal from the firstend of the vessel the same as said distance of a stage that is a secondor subsequent stage and configured to feed a gas stream into the vessel;

one or more aqueous phase inlets configured to feed an aqueous phaseinto the second end of the vessel or proximate thereto;

one or more hydrate slurry outlets configured to draw off a hydrateslurry stream from the first end of the vessel or proximate thereto;

one or more gas product outlets configured to draw off a gas productstream from the second end of the vessel or proximate thereto; and

a temperature control system effective to establish a temperaturegradient or a series of temperature steps from a first temperature T₁ ina region proximate to the first end of the vessel to a secondtemperature T₂ in a region proximate to the second end of the vessel,and controlling the temperature at each of the stages, wherein T₁>T₂;

wherein the gas stream and the aqueous phase flow in a countercurrentmanner through the vessel.

The hydrate forming reactor accomplishes intimate mixing of the gas andaqueous phases in a countercurrent flow. Apparatus and methods formixing gases and aqueous phases are known, and include bubbling of gasthrough a column of the aqueous phase, venturi-type mixers, “bubbletray” or “liquid tray” arrangements within towers that are contactedwith a flow of the liquid phase or with a flow of the gas phase,respectively, and distribution of the aqueous phase as a mist or finedroplets that are carried through the gas phase or fall through it underthe influence of gravity. See, for example, U.S. Pat. No. 2,410,583,U.S. Pat. No. 5,434,330, U.S. Pat. No. 6,111,155, U.S. Pat. No.6,028,234, U.S. Pat. No. 6,797,039 and US20130012751, all herebyincorporated by reference in their entirety and for all purposes.

The hydrate forming reactor also comprises a series of stages, which areestablished by creating zones within the reactor that are controlled toa selected temperature by either refrigeration or heating as necessary.For example, in a reactor in which a flow of gas upward is contacted bya flow of aqueous phase as a falling mist, zones of defined temperaturecan be established by baffles perforated by riser tubes, each bafflebeing configured to carry a heat exchange fluid so as to control thetemperature of the baffle and associated riser tubes to a selectedtemperature by heating or refrigeration of the heat exchange fluid. Asanother example, in a “tray” arrangement, the temperatures of each ofthe trays can be individually controlled.

A gas feed inlet to the HFR is configured to feed a gas stream into thevessel. The gas feed can be located at the first end (which can be thebottom, if the HFR is oriented vertically) of the vessel encompassingthe HFR, but is typically located some distance from the first end sothat a “feed stage” can be established that is somewhat distal from thefirst end, allowing for separation stages upstream (for the gas flow)from the gas feed inlet. The particular form of the gas feed inlet willdepend upon the overall design of the HRF. For example, if a feed isbubbled into the reactor, a sparger or an arrangement of a plurality ofsmall nozzles might be used as the gas inlet. Heating or coolingapparatus, a pump or compressor, and the like, can be incorporated intoa gas feed inlet to the HFR. Control of the gas feed, including of itstemperature and pressure, is considered well-known in the art.

The gas feed inlet of the HFR can be configured to include an inlet thatallows for introducing a hydrate promoter into the gas phase.

An aqueous phase inlet is configured to feed an aqueous phase into thevessel. An aqueous phase inlet can include an input for fresh, “make-up”water.

The aqueous phase inlet is typically placed at the second end of thevessel that encompasses the HFR, although alternative arrangements arealso envisioned in which a number of aqueous phase inlets are provideddistributed along the length of the HFR proximate to the second end ofthe HFR. As for the gas inlet, the specific form of the aqueous phaseinlet will depend on the overall design of the HFR. For example, if thecounterflow of the aqueous phase is in the form of a falling mist, theaqueous phase inlet can be arranged as a plurality of fine nozzlesdisposed around the circumference of the top of the HFR that is orientedvertically.

The aqueous phase inlet can be configured to include a mixer forintroducing an amount of one or more hydrate promoters, in either liquidor solid form, into the aqueous phase.

The aqueous phase inlet can also be configured to include a mixer forintroducing one or more inorganic or organic salts or surfactants intothe aqueous phase. The salt(s) may be added in solid form or as asolution. A salt solution of the aqueous phase allows chilling of theaqueous phase to temperatures below 32° F. (0° C.). Ocean water may beused as the aqueous phase.

The form of the hydrate slurry outlet(s) of the HFR is considered knownin the art and again the specific form will depend on the overall designof the HFR and also to the form of the hydrate (e.g. particle size) andits concentration in the slurry.

The form of the one or more gas product outlets is also considered knownin the art, and again the specific form will depend on the overalldesign of the HFR. The end use of the product gas will be considered inselecting the form of the gas product outlet. For instance, if theproduct gas is to be discharged to the atmosphere as a pure gas, asimple pressure release valve can suffice. On the other hand, if theproduct gas is to be used to drive a turbine, then the product gasoutlet will be configured with appropriate couplings for attaching to agas pipeline or storage vessel and to appropriate pressure controls.

A system for separating CO₂ from combustion or other gases can include aplurality of HFRs arranged in series. In such an arrangement, thehydrate product from a first HFR is decomposed and the gas released fromthe first decomposed hydrate is used as the gas feed (which can be mixedwith, e.g. a hydrate promoter as described below) into a second HFR.Such a second or yet additional HFR(s) can be operated at the samepressure and/or temperature as the first HFR, or can be operated at areduced pressure and/or different temperature gradient or step series,compared to the pressure and temperatures in the first, or upstream HFR(e.g., 2200 psia for the first of two HFRs, and 1000 psia for the secondof two HFRs). A measurement of the composition of gas released from thedecomposed hydrate obtained from an upstream HFR or calculation of thecomposition of the hydrate from equilibrium principles can be used toset the composition of the input gas for calculation of the staging tobe used in a respectively downstream HFR.

In an alternative arrangement, the slurry from the first HFR istransported to a second HFR for use in the aqueous phase, and differentconditions of pressure and/or temperature are used in the second reactorto change the hydrate composition. Whatever gas is released during apressure change can be combined with the N₂-rich phase for powerrecovery, or put to another industrial use, or vented to the atmosphereif the gas does not contain a lot of CO₂.

A hydrate formation promoter can be added to either the gas stream or tothe aqueous phase. Hydrate formation promoters can be of either thethermodynamic or kinetic type. A thermodynamic hydrate formationpromoter (“THP”) changes the equilibrium conditions for hydrateformation and will lower the pressure at which hydrates are able toform. A kinetic hydrate formation promoter (“KHP”) accelerates the rateof hydrate formation without changing the equilibrium conditions.Examples of THPs include acetone, propane, isobutane, cyclopentane,carbon tetrachloride, bromoform, chloroform, ethylene dichloride,methylene chloride, methyl iodide,methylene iodide, and the tri-halogencompounds of methane and ethane, propylene oxide, 1,4-dioxane,tetrahydrofuran and H2S, surfactants (e.g. TBAB—Tetra n-Butyl AmmoniumBromide, TBAF—Tetra n-Butyl Ammonium Fluoride, TBACl—Teta n-ButylAmmonium Chloride), and enzymes (glucoamylase). Examples of KHPs includesurfactants (e.g. SDS—Sodium Dodecyl Sulfate, DTAC—Dodecyl TrimethylAmmonium Chloride) and inorganic or organic salts (e.g. NaCl).

A system for separating CO₂ from combustion or other gases can furtherinclude a solid-liquid (SLS) separator configured to receive an aqueoushydrate slurry from the hydrate slurry outlet for separation into anaqueous phase product and a solid hydrate. The SLS can be integral withthe HFR at the first end of the vessel. In such an instance of a SLSintegral with the HFR, the hydrate slurry outlet can be replaced by anoutlet suitable for conveying a solid hydrate material from the HFR andan outlet suitable for conveying an aqueous phase from the HFR. Thehydrate product of the SLS can be collected and transported and/orsequestered as a concentrated hydrate product, or decomposed asdescribed further below.

When the system includes a SLS, the system can further include anaqueous phase recirculation line that connects a reservoir or pipe ofthe SLS holding the recovered aqueous phase to the vessel of the HFR,typically via the aqueous phase inlet, but in some embodiments aseparate inlet for the recirculating aqueous phase can be provided.Aqueous phase recovered from the hydrate separation can be recirculatedback to the HFR via this line. The aqueous phase recirculation line caninclude a cooling plant to cool the aqueous phase prior to introducingthe recycled aqueous phase back into the HFR. The aqueous phaserecirculating line can alternatively or additionally include an inletfor adding a kinetic hydrate promoter to the recirculating aqueousphase.

A system for separating CO₂ from a mixture of gases comprising N₂ canadditionally or alternatively include a hydrate decomposition facility(“HDF”). The HDF can be operably connected directly to the hydrateslurry outlet of the HFR, or the HDF can be operably connected toreceive the concentrated hydrate product (which can be in the form of aconcentrated slurry or a solid) from the SLS. A HDF generally comprisesa hydrate decomposition plant (“HDP”) and a vapor-liquid separator(“VLS”)

The hydrate decomposition plant decomposes the hydrate into itscomponent gas(es) and an aqueous phase comprising the empty clathrateand water. The decomposition can be effected by either heating of thehydrate or reducing the pressure under which it is kept, or acombination of both. Accordingly, the HDP can contain either or both ofa heater for raising the temperature of the hydrate or apparatus forlowering the pressure under which the hydrate is maintained at theoutlet of the HFR or SLS.

The HDF further includes a VLS for separating a vapor product from anaqueous phase. The VLS is configured such that the vapor product of theVLS is collected and stored and/or transported for use in anotherindustrial process. The VLS can be further configured so that theaqueous phase liquid product is returned to the vessel of the HFR via anaqueous phase recirculating line. The aqueous phase recirculating linecan include a cooling plant for cooling the aqueous phase liquidproduct. Additionally or alternatively, the aqueous phase recirculatingline can include an input for adding a hydrate promoter and/or aninorganic or organic salt to the aqueous phase.

Unless otherwise indicated, for instance by more detailed description,movement of gases and fluids, and control of their temperature andpressure, is considered known in the art. Accordingly, the flow lines,inlets and outlets described herein may be considered to includeapparatus for moving and controlling the flow of fluids between andwithin components of the systems disclosed, such as pumps, compressors,valves of different kinds, meters, feedback controls, digital controlsand the like, as one of ordinary skill in the art would expect to use.

FIG. 4 illustrates an embodiment of a system for hydrate-based gasseparation. A feed gas stream 1 enters a hydrate formation reactor (HFR)3 via a gas inlet 5 located at a gas feed stage 7. The gas feed stage ismaintained at a temperature T_(f). The gas stream flows incountercurrent fashion in contact with an aqueous phase stream 9,through a stage n and out a product gas outlet of the HFR 11. Stage n ismaintained at a temperature T₂. The product gas 13 is stored, put to useor vented to the atmosphere.

The aqueous phase stream enters the hydrate formation reactor via anaqueous phase inlet 15 and flows countercurrent to the gas stream andexits the hydrate formation reactor as a hydrate slurry 17 via a hydrateslurry outlet 19. The aqueous phase hydrate slurry is transported to ahydrate decomposition facility 21 that includes both a hydratedecomposition plant (HDP) and a vapor-liquid separator (VLS). Thehydrate is decomposed in the HDP into the component gas(es) and theaqueous phase (water or a water solution) by operation of a heater or bylowering the pressure under which the hydrate is maintained. Theresulting gas(es) and aqueous phase are separated one from another inthe VLS to obtain a captured gas 23 and regenerated aqueous phase 25.The regenerated aqueous phase leaves the VLS via an aqueous phaserecirculating line 27. The regenerated aqueous phase is recirculated tothe HFR via the aqueous phase inlet. The aqueous phase recirculatingline optionally includes a cooling plant 29 for cooling the aqueousphase. The aqueous phase recirculating line also includes a bleed 31 fordrawing off portions of the aqueous phase. The aqueous phaserecirculating line, and/or the aqueous phase inlet of the HFR, containsa water make-up inlet 33 for introducing fresh water into the system.The concentration of solutes in the aqueous phase can be adjusted byadding fresh water and/or removing aqueous phase via the water make-upand bleed.

FIG. 5 illustrates another embodiment of a system for hydrate-based gasseparation. A feed gas stream 1 enters a hydrate formation reactor (HFR)3 via a gas inlet 5 located at a gas feed stage 7. The gas feed stage ismaintained at a temperature T_(f). The gas stream flows incountercurrent fashion in contact with an aqueous phase stream 9,through a stage n and out a product gas outlet of the HFR 11. Stage n ismaintained at a temperature T₂. The product gas 13 is put to use orvented to the atmosphere.

The aqueous phase stream enters the hydrate formation reactor via anaqueous phase inlet 15 and flows countercurrent to the gas stream andexits the hydrate formation reactor as a hydrate slurry 17 via a hydrateslurry outlet 19. The aqueous phase hydrate slurry is transported to ahydrate separator plant 25 in which the hydrate slurry is separated intoa captured gas-rich hydrate 37 (which may include some residual aqueousphase) and regenerated aqueous phase 25. The regenerated aqueous phaseleaves the VLS via an aqueous phase recirculating line 27. Theregenerated aqueous phase is recirculated to the HFR via the aqueousphase inlet. The aqueous phase recirculating line optionally includes acooling plant 29 for cooling the aqueous phase. The aqueous phaserecirculating line also includes a bleed 31 for drawing of portions ofthe aqueous phase. The aqueous phase recirculating line, and/or theaqueous phase inlet of the HFR, contains a water make-up inlet 33 forintroducing fresh water into the system. The concentration of solutes inthe aqueous phase can be adjusted by adding fresh water and/or removingaqueous phase via the water make-up and bleed.

The captured gas-rich hydrate can be sequestered, e.g. by placement in ageologic formation or in the ocean, optionally after encapsulation ofthe hydrate, or stored or transported for further industrial use.

Also provided is a process for purifying CO₂ from a gas comprising N₂.The process includes contacting a feed gas stream comprising CO₂ and N₂gases and a aqueous phase stream in a countercurrent flow to form aCO₂-rich hydrate in the aqueous phase, a temperature T_(f) beingmaintained at a gas feed stage f in the countercurrent flow, atemperature T₂ such that T₂<T_(f) being maintained at a stage n>f, and atemperature T₁ being maintained at a stage m<f such that T₁≥T_(f);

wherein:

T₂ is in the range from the incipient vapor temperature for CO₂ to theincipient hydrate temperature for CO₂ at the operating pressure of theprocess, and

T₁ is a temperature at or below a temperature of convergence of theincipient CO₂ hydrate and incipient CO₂ vapor curves at the operatingpressure of the process.

The gas of the gas feed stream is preferably one that includes somenitrogen. Typically gas resulting from combustion in air or anoxygen-rich atmosphere of a hydrocarbon or alcohol fuel, or a mixturethereof, is separated. Flue gas from a hydrocarbon-fired power plant,such a Natural Gas Combined Cycle or coal-fired power plant, can beseparated in the present method. The feed gas can comprise CO₂ that hasbeen concentrated by a prior-applied process, such as the knownamine-based CO₂ capture process. FIG. 8 schematically illustrates suchan amine-based CO₂ capture process.

The CO₂ in the gas feed is separated from at least N₂ and other gases byintimately contacting the gas feed stream with a stream of an aqueousphase under certain conditions of pressure and temperature in acountercurrent flow. The countercurrent flow and the conditions oftemperature and pressure establish a series of “stages” in the HFR. Theprocess is run isobarically within any one HFR, and so the stages of theseparation in any one HFR are determined by variations in temperature.The equilibrium concentrations of CO₂ and N₂ and other gases in each ofthe gas and hydrate phases change at each stage. The process can beconducted using only one stage. In such an instance, T_(f)=T₁=T₂.Typically the process is conducted using at least two stages. In anyevent, the stages can be considered as a first stage at the lowesttemperature in separation step, one or more—up to n—stages atprogressively higher temperatures and a gas feed step f, which is thestage at which the gas feed inlet to the HFR is located. The gas feedstage can be at any stage. The gas feed stage is typically the first,second or third stage, most typically the second or third stage.

The design of the separation, that is determination of the overalloperating pressure of the separation process, and the number of stagesand their temperature can be performed using calculations fromequilibrium principles, in the manner similar to the calculations fordesigning a distillation of a binary liquid.

Separation in the proposed multistage configuration is driven by varyingoperating conditions, in this instance temperature, at each stage. Asingle HFR system utilizes is run isobarically using differenttemperatures for different stages. Stages can be implemented instead asa chain of coupled HFRs, each designed to run at different pressures.

At any given operating pressure, addition of warmer stages below the gasfeed stage results in improved CO₂ purity and N₂ recovery, whereasaddition of cooler stages above the gas feed stage result in improved N₂purity and CO₂ recovery.

For determination of the operating pressure of the process, the feed gascomposition is located along the x-axis of a plot of composition (asmole fraction) vs. incipient hydrate formation pressure for a CO₂—N₂binary gas (FIG. 1). Power plant flue gas, typically has a compositioncomprising from about 5 mol % CO₂ and about 95% other gases,substantially N₂, but also minor amounts of other gases, to about 20 mol% CO₂ and about 80% other gases, again, substantially N₂ mixed withminor amounts of other gases. As shown in FIG. 1, (showing only a binarymixture of CO₂ and N₂) the operating pressure of the process is at leastabout 140 atm (about 2100 psia) at 33° F. (0.5° C.).

A phase diagram (composition as mol % vs. temperature), similar to aboiling point diagram of a binary liquid mixture, can then be calculatedfor the vapor-liquid (V-L), vapor-liquid-hydrate (V-L-H) andliquid-hydrate (L-H) phases of the binary mixture at the selectedpressure. FIG. 2 shows the calculated phase diagram of a CO₂/N₂ binarymixture at 2200 psia. Staging for the separation can then be derivedeither from a McCabe-Thiele plot of the equilibrium composition of vaporand hydrate at a desired pressure (typically the lowest pressure, ornearly so, that provides for hydrate formation of the feed gascomposition), and then observing the temperatures at the incipienthydrate formation curve at the composition indicated for each of thestages.

Alternatively, staging can be designed by calculating phase diagrams forvapor-liquid (v-l), vapor-liquid-hydrate (v-l-h) and liquid-hydrate(l-h) phase diagrams for a feed gas composition, of the two gases to beseparated (N₂ and CO₂, for example, as below) for mol % of one of thegases to be separated from the feed gas vs. temperature at a givenpressure. A temperature for the first stage can be selected by picking atemperature between the equilibrium incipient hydrate formation curveand incipient vapor formation curve at the composition desired in thehydrate phase. A temperature of the last stage is then selected bypicking the temperature on the incipient vapor formation curve at thecomposition desired in the gas captured in the hydrate. Temperatures ofintermediate phases, if any, are then identified by noting thecomposition of the incipient vapor at the temperature selected for thefirst stage, then noting the temperature of the incipient hydrateformation curve at this composition as the temperature for the secondstage. The temperature of the third stage is selected by noting thecomposition at the incipient vapor formation line at the temperature ofthe second stage, then noting the temperature of the incipient hydrateformation line at this composition, etc.

FIG. 6 illustrates the determination of staging in the separation usingthe equilibrium curves as described above. A phase diagram for a gasbinary mixture is calculated from equilibrium principles at a selectedoperating pressure to generate an incipient hydrate formation curve 111and an incipient vapor formation curve 113. The plot is of temperaturevs.

composition (in mol %) of the binary mixture, similarly as a “boilingpoint” diagram used to design a distillation process. In FIG. 4 themixture is of CO₂ and N₂ and the pressure is 2200 psia. A compositionfor the gas feed is chosen, and then a temperature in the range betweenthe incipient hydrate formation curve 111 and an incipient vaporformation curve incipient hydrate formation curve and an incipient vaporformation curve is selected for the first stage temperature (Ta, in thisinstance 31° F.). A first “operating line” 115 is drawn at thetemperature to the incipient vapor formation line. The intersectionprovides the composition of the gas at the next stage. The temperatureat that composition shown on the incipient hydrate formation curveprovides the temperature (Tb) of the next stage. A second operating line117 is drawn to determine the composition of the gas at the next stage,which is in turn used to find the temperature for the next stage (Tc) ata third operating line 119. The iteration continues to identify a fourthtemperature (Td) at a fourth operating line 121. A separation run inaccord with this design is expected to provide purification of CO₂/N₂mixture of 5 mol % CO₂/95 mol % N₂ to a composition of 90 mol % CO₂/10mol % N₂.

We have developed a computational model of the hydrate-based separationprocess. The model includes a combination of hydrate formationthermodynamics and the multistage countercurrent operation, andgenerates results from these known principles. See, e.g. E. Dendy SloanJr. and C. Koh, “Clathrate Hydrates of Natural Gases”, Third Edition,CRC Press, 2007 and A. L. Ballard and E. Dendy Sloan Jr., “The nextgeneration of hydrate prediction: An overview”, Journal ofSupramolecular Chemistry, vol. 2, pp. 385-392 (2002). Both of thesereferences are hereby incorporated by reference in their entirety andfor all purposes. The integrated model takes as inputs feed compositionand operating conditions and iteratively generates phase fractions andcompositions as outputs.

A process for separating CO₂ from a gas mixture comprising N₂ canfurther include separating the gas stream from the aqueous phase afterthe contacting step and collecting a hydrate slurry formed in theaqueous phase and comprising hydrate particles enriched in CO₂. Aprocess can further include concentrating the hydrate from the hydrateslurry and sequestering the hydrate from the atmosphere. The collectingand concentrating can be effected by a solid-liquid separator. Thesolid-liquid separator may, for example, include a device such as aconveyor belt or spinning drum separator. In other embodiments, thehydrate may be separated by falling through a tower, e.g. as describedin US20130012751, hereby incorporated by reference. The separatedhydrate can be sequestered on the deep ocean floor or buried in the seafloor at a depth sufficient to maintain the hydrate phase. See, e.g., F.Qanbari et al., “CO₂ disposal as hydrate in ocean sediments,” Journal ofNatural Gas Science and Engineering, vol. 8, p. 139 (2012); F. Qanbariet al., “Storage of CO₂ as hydrate beneath the ocean floor,” EnergyProcedia, vol. 4, p. 3997 (2011).

Additionally or alternatively, the hydrate can be encapsulated tosequester the host gas (CO₂). The sequestered hydrate can be stored onthe deep ocean floor or in the sea floor at a depth sufficient tomaintain the hydrate phase.

The separated hydrate can also be stored and/or transported for use in afurther industrial process. Alternatively, the hydrate can bedecomposed, by increasing the temperature at which it is maintained, bydecreasing the pressure at which it is maintained, or by a combinationof both.

The CO₂ gas released by the hydrate decomposition (“captured gas”) canthen be transported for use in a further industrial process or injectedinto a geologic formation either to sequester it or to pressurize ahydrocarbon production field. Alternatively, the captured gas can beused as a feed into an iteration of the separation process that is rununder conditions appropriate to the input captured gas composition.

Additionally or alternatively, the product gas of the separation, forexample a N₂-rich gas, can be collected after the step of contacting thegas with the aqueous phase. The collected product gas can be storedunder a pressure above atmospheric pressure or transported underpressure to be used for generating energy, e.g. by moving a turbine, orto do other useful work as a compressed gas. Alternatively, the productgas might be adjudged sufficiently pure to be released into theatmosphere or used as an input substance to an industrial process.

In one embodiment of a separation of CO₂ from a gas mixture comprisingN₂, the process is conducted at 2200 psia, T₂ is from 31 to 34° F. (−0.5to 1.1° C.) and T₁ is about 54° F. (12.2° C.).

In another embodiment of a separation of CO₂ from a gas mixturecomprising N₂, the hydrate separation is conducted in 3 stages and T_(f)is about 33° F. (0.5° C.), T₁ is about 35° F. (1.6° C.) and T₂ is about31° F. (−0.5° C.).

In any embodiment of the process, the feed gas stream can include ahydrate promoter. Additionally or alternatively, in any embodiment ofthe process, the aqueous phase stream can include a hydrate promoter.

FIG. 7 illustrates the flow of the disclosed process. At 1001, a feedgas is provided in a gas stream that at 1003 is contacted with anaqueous phase stream to form a hydrate in the aqueous phase stream, andthe gas stream and aqueous phase stream are separated one from theother. At 1005, the hydrate is separated from the aqueous phase and at1007 is stored or transported for use in another industrial process, oris sequestered (1007 a) or decomposed and separated into its componentgas(es) and aqueous phase (1007 b). At 1009, the gas obtained fromdecomposition of the hydrate is stored for transport or used directly ina further industrial process or transported for injection into ageologic formation (1009 a), or used as a feed to a downstream iterationof the process (1009 b).

At 1011, the aqueous phase obtained from the hydrate separation can berecycled to the countercurrent flow (1011 a) or transported forinjection into a geologic formation or sent to waste (1011 b).

At 1013, the gas product of the countercurrent separation is collectedand stored o transported for further industrial use (1013 a), used as afeed to a downstream iteration of the process above (1013 b), stored ortransported under pressure to generate electricity, e.g. by driving aturbine or to do other useful work (1013 c), or if sufficiently pure tomeet regulatory standards, vented to the atmosphere, e.g. as N₂-rich gas(1013 d).

EXAMPLES

The following examples of gas separations are intended to beillustrative only and not limiting of the scope of the invention, whichis defined solely by the claims following. Example separations of CO₂from N₂ are simulated by a computational model. The model includes acombination of hydrate formation thermodynamics and multistagecountercurrent tower operation. The integrated model takes as inputsfeed composition and operating condition and iteratively generates phasefractions and compositions as outputs.

Example 1 Pressure Requirement for Hydrate Formation

As a first step to study the CO₂—N₂ system, simulations are used toestimate the minimum pressure required for hydrate formation. FIG. 1shows the minimum pressure requirement as a function of N₂ mole fractionin the feed gas. As the feed becomes dilute in CO₂, the pressurerequirement for hydrate formation increases exponentially. The instanceof NGCC flue gas comprising ˜5% CO₂ is shown, and a requirement for afairly high minimum pressure (˜2035 psia) to obtain hydrate formation isfound.

The minimum pressure requirement for feeds containing higherconcentrations of CO (e.g., biogas, landfill gas) are not so high (e.g.,feed containing 50% CO₂ requires a minimum pressure of 413.9 psia).Thus, using a CO₂ concentrating process ahead of the hydrate-formationbased separation process can provide for use of lower operatingpressures and/or higher operating temperatures for the hydrateformation-based process.

To understand the sensitivity of the minimum required pressure withoperating temperature, the temperature of the simulation was varied from33° F. to 39° F. for a mixture of 5% CO₂—95% N₂ as the feed. FIG. 9shows that pressure requirement for hydrate formation increasessignificantly as temperature increases (by ˜150 psia per ° F.).Therefore, for the 5% CO₂—95% N₂ separation system, it appears that thepreferred temperature for a single stage operation is 33° F. or lower.

Example 2 Operating Temperature Window

To determine the temperature range for a separation at a fixed pressure,simulation is conducted at various CO₂/N₂ feed compositions and aselected pressure. FIG. 2 shows the complete operating temperaturewindow at a fixed pressure of 2200 psia. The incipient hydrate curveindicates the temperature below which the hydrate phase exists (i.e.,the maximum allowed temperature for hydrate formation). The incipientvapor curve indicates the temperature below which there is no vaporphase. The available operating window for the separation is the regionbetween these two curves.

Example 3 Process Modeling of the CO₂—N₂ System

Our process model conducts the thermodynamic calculations for equilibriaat every stage, and iteratively converges the system of equations thatdescribe a countercurrent equilibrium separation. At each stage of amultistage separation, feed composition and operating conditions areused to estimate the thermodynamic equilibrium-based phase fractions andcomposition.

With this generalized model, we are able to evaluate single stage andmulti-stage, counter-current configurations for separation performancein terms of recovery and purity.

The simulation is applied to the case of a 5% CO₂—95% N₂ feed. Thetemperature range for the simulation is arbitrarily set from 31 to 35°F. Results are shown in FIGS. 4 and 5, and summarized in Table 1. A3-stage countercurrent tower is sufficient to provide >90% CO₂ capturein the combined aqueous and hydrate phases, at a pressure of 2200 psia.An N₂-rich product gas stream is 99.5% pure; it can be used for somepower recovery or discarded to the atmosphere. 90.9% of the input N₂ isrecovered in this product gas stream. As shown in FIG. 4, if allcaptured CO₂ is recovered from the aqueous and hydrate phases, theoverall CO₂ recovery is 92.6% in the gas stream. On the other hand, ifCO₂ is captured in the hydrate phase for sequestration, but some CO₂ isdissolved in the aqueous phase (FIG. 5), the overall CO₂ recovery inhydrate phase is 38.4%. Recycling water with dissolved CO₂ willinfluence the tower performance.

FIG. 2 shows the operating window for a separation of CO₂ from N₂ at2200 psia. Convergence of the incipient hydrate formation curve and theincipient vapor formation curves at ˜90% indicates the maximum CO₂purity that can be achieved using multiple stages. Table 1 summarizesthe results of simulations of the system configurations shown in FIGS. 4(capture in hydrate and eventually recovered as gas) and 5 (capture inhydrate and aqueous phase).

TABLE 1 Representative performance of a multistage hydrate-basedcountercurrent separator. Feed contains 95% N₂, 5% CO₂, and excesswater, corresponding to a typical NGCC flue gas. Pressure is fixed at2200 psia. A highly pure N₂ stream (99.5%) can be recovered at the top,which can be used for power recovery and later on discarded safely. CO₂is captured in both hydrate and aqueous phases. 38-93% CO₂ is capturedfrom the flue gas. Captured CO₂ stream has a moderate purity between23-35%, which is a substantial improvement over the flue gas CO₂ purity(5%). Primary mechanism Hydrate + Aqueous for CO₂ capture — HydrateSolubility CO₂ recovery —   38%   93% CO₂ purity  5%   23%   35% N₂recovery —   91%   91% N₂ purity 95% 99.5% 99.5%

Example 4 Effect of Operating Conditions on the Operating Window

FIG. 2 shows the operating temperature window for the CO₂/N₂ separationsystem at a pressure of 2200 psia. This example demonstrates theindividual effects of pressure (FIG. 11) and H₂S additive concentration(FIG. 12) on the operating temperature window.

Conditions for the simulation other than pressure and additiveconcentration are the same as those in FIG. 2. At lower pressure, theoperating temperature window is narrower, especially for the inletcomposition of 5% feed CO₂, i.e., the HFR operation is more challengingdue to the narrow temperature range of the operating window. With theaddition of H₂S, the operating temperature window becomes wider, i.e.,the HFR operation becomes easier due to wider temperature range.

Widening of temperature window is an opportunity for decreasing theoperating pressure. Accordingly, simulations are conducted with 5% H₂Saddition at lower pressure (750 psia). The results are shown in FIG. 13.

There are many such additives that could be used to widen the operatingwindow. A simulation is run to show the effect of anotheradditive—iso-butane—on the operating window. Results are shown in FIG.14. Even a small quantity of iso-butane in the feed results in asignificant effect of reducing the minimum operating pressure.

1. A system for separation of CO₂ from combustion product or other gascomprising a hydrate formation reactor (HFR) that comprises an outervessel configured: with a plurality of stages arranged with a firststage proximal a first end of the vessel and second and any subsequentstages successively more proximal a second end of the vessel; one ormore gas feed inlets placed at a distance from the first end of thevessel the same as said distance of a stage that is a second orsubsequent stage and configured to feed a gas stream into the vessel;one or more aqueous phase inlets configured to feed an aqueous solutioninto the first end of the vessel or proximate thereto; one or morehydrate slurry outlets configured to draw off a hydrate slurry streamfrom the first end of the vessel or proximate thereto; one or more gasproduct outlets configured to draw off a gas product stream from thesecond end of the vessel or proximate thereto; and a temperature controlsystem effective to establish a temperature gradient or a series oftemperature steps from a first temperature T₁ in a region proximate tothe first end of the vessel to a second temperature T₂ in a regionproximate to the second end of the vessel, and controlling thetemperature at each of the stages, wherein T_(1>)T₂; wherein the gasstream and the aqueous phase flow in a countercurrent manner through thevessel.
 2. The system of claim 1 that further comprises a solid-liquidseparator configured to receive an aqueous hydrate slurry from thehydrate slurry outlet for separation into an aqueous phase product and asolid hydrate.
 3. The system of claim 2 in which the solid-liquidseparator comprises an aqueous phase recirculating line that feeds theaqueous phase product of the solid-liquid separator into the vessel. 4.The system of claim 3 in which the recirculating line includes a coolingplant for cooling the aqueous phase liquid product.
 5. The system ofclaim 1 that further comprises a hydrate decomposition facilityincluding a hydrate decomposition plant for decomposing a hydrate and avapor-liquid separator for separating a vapor product from an aqueousphase and that is operably connected to the hydrate formation reactor soas to receive a hydrate slurry from the hydrate slurry outlet of thehydrate formation reactor.
 6. The system of claim 5, in which thehydrate decomposition plant comprises a heater for raising thetemperature of the hydrate.
 7. The system of system of claim 5, in whichthe hydrate decomposition plant is one that lowers the pressure of ahydrate slurry.
 8. The system of claim 5, that further comprises anaqueous phase recirculating line that feeds the aqueous phase product ofthe vapor-liquid separator into the vessel.
 9. The system of claim 8, inwhich the aqueous phase recirculating line includes a cooling plant forcooling the aqueous phase liquid product.
 10. The system of claim 1 thatfurther comprises an inlet for adding a hydrate promoter to the gas feedstream.
 11. The system of claim 2 that further comprises an inlet foradding a hydrate promoter to the gas feed stream.
 12. The system ofclaim 8 that further comprises an inlet for adding a hydrate promoter tothe gas feed stream.
 13. The system of claim 3, wherein the aqueousphase recirculating line includes an input for adding a hydrate promoterto the aqueous phase.
 14. The system of claim 8, wherein the aqueousphase recirculating line includes an input for adding a hydrate promoterto the aqueous phase.
 15. The system of claim 12, wherein the aqueousphase recirculating line includes an input for adding a hydrate promoterto the aqueous phase.
 16. The system of claim 13 that further comprisesan inlet for adding a hydrate promoter to the gas feed stream.
 17. Thesystem of claim 1, in which the product gas outlet(s) are configured totransport the product gas to a storage facility for storing the productgas at a pressure above atmospheric pressure.
 18. The system of claim 1,in which the product gas outlet(s) are configured to transport theproduct gas to a turbine for generating electricity.
 19. A process forpurifying CO₂ from a gas comprising N₂, the process comprisingintimately contacting a feed gas stream comprising CO₂ and N₂ gases andan aqueous phase stream in a countercurrent flow to form a CO₂-richhydrate in the aqueous phase, a temperature T_(f) being maintained at agas feed stage f in the countercurrent flow, a temperature T₂ such thatT₂<T_(f) being maintained at a stage n>f, and a temperature T₁ beingmaintained at a stage m≤f such that T₁≥T_(f); wherein: T₂ is in therange from the incipient vapor temperature for CO₂ to the incipienthydrate temperature for CO₂ at the operating pressure of the process,and T₁ is a temperature at or below a temperature of convergence of theincipient CO₂ hydrate formation and incipient CO₂ vapor formation curvesat the operating pressure of the process.
 20. The process of claim 19,further comprising separating the gas phase from the aqueous phase andcollecting a hydrate slurry formed in the aqueous phase and comprisinghydrate particles enriched in CO₂.
 21. The process of claim 20, furthercomprising concentrating the hydrate from the hydrate slurry andsequestering the hydrate.
 22. The process of claim 21, in which thehydrate is sequestered on the deep ocean floor or buried in the seafloor, or in which the hydrate is encapsulated.
 23. The process of claim19, further comprising collecting a N₂-rich gas from the gas streamafter contact with the aqueous phase.
 24. The process of claim 20,further comprising collecting a N₂-rich gas from the separated gas. 25.The process of claim 24 that is conducted at 2200 psia, T₂ is from 31 to34° F. (−0.5 to 1.1° C.) and T₁ is about 54° F. (12.2° C.).
 26. Theprocess of claim 24, in which there are 3 stages and T_(f) is about 33°F. (0.5° C.), T₁ is about 35° F. (1.6° C.) and T₂ is about 31° F. (−0.5°C.).
 27. The process of claim 19, in which the feed gas stream comprisesa hydrate promoter.
 28. The process of claim 19, in which the aqueousphase stream comprises a hydrate promoter.
 29. The process of claim 27,in which the aqueous solution stream comprises a hydrate promoter.